Carton construction



Dec. 6, 1966 J, Wl BQYD ETAVL 3,289,911

CARTON CONSTRUCTION Filed March 5, 1965 Sheets-Sheet l Dec. 6, 1966 J. w. BOYD ETAT. 3,289,911

CARTON CONSTRUCTION Filed March 6, 1965 .f5 Sheets-Sheet 2 Dec 6, 1966 J. w. BOYD ETAL CARTON CONSTRUCTION 5 Sheets-Sheet 5 Filed March 5, 1965 United States Patent 3,289,911 CARTON CNSTRUC'IION .lames William Boyd, Crown Ioint, Ind., and Dick Leroy 'Flodder-f, Calumet City, Ill., assigner-s, by mesne assignments, to Packaging Corporation of America, a

corporation of Delaware Filed Mar. S, 1965, Ser. No. 437,446 3 Claims. (Cl. 229--2.5)

This invention relates to a carton construction and more particularly to a molded self-locking type of carton which is adapted for use primarily in the packaging of fragile articles such as eggs or the like.

Cartons of this type are normally formed of molded paper-pulp and are either a 3 X 4 or 2 x y6 style. In the one style carton there `are three parallel rows of articleaccommodating pockets with four pockets to a row, and in the other. style carton there are two parallel rows of six pockets to each row.

Various self-locking cartons have heretofore been proposed which utilize a latching flap that is hingedly mounted on the tray and is adapted to interlock with an apertured wall formed on the cover when the latter is in a closed position. In one form of such carton, the flap is adapted to overlie the aperture wall of the closed cover and has tabs formed on the flap, which are adapted to project inw-ardly through and interlock with the cover wall apertures. A carton of this form is disclosed in the I. W. Cox Patent 2,517,465. A second form of a well known self-locking carton is that disclosed in the R. F. Reifers Patent No. 2,990,094. In this latter carton the latching iiap is adapted to assume a position behind the aperture wall of the cover is in its closed position. The flap in this instance is provided with a pair of protruding lugs which are adapted to project outwardly through registered apertures formed in the cover wall. In order to insure that a positive interlockin-g engagement is effected between the cover and ap it is important that the flap lugs extend a substantial distance through the cover aperture.

With either of the Cox or Reifers style carton there is a serious problem of `accidential opening of the carton while it is being handled by the packer, merchandiser, or customer. In the Cox type carton substantial part of the latching flap is exposed and thus susceptible to being accidentally torn open. In the Reifers type carton, the locking lugs vare readily exposed and are susceptible to being accidentally pushed in resulting in unlocking the carton and/or causing damage to the articles disposed within the row of pockets adjacent the flap.

Thus, it is one of the objects of this invention to provide a self-locking carton which is not beset with the aforementioned shortcomings of either the Cox or Reifers type cartons.

It is a further object of this invention to provide a self-locking carton which is possessed of -an effective lock for the cover, may have the lock components readily formed at the time the carton is bein-g molded, and is capable of being loaded and closed either manually or by automatic equipment.

It is a further object of this invention to provi-de -a self-locking carton which will not interfere with the loading of eggs or other fragile articles therein, and will not detract from the esthetic appearance of the carton.

It is a still further orb-ject of this invention to provide a self-locking carton which will automatically lock the cover in place even after repeated opening of the cover, and yet, may be readily opened, when desired, by the housewife or customer.

Further and additional objects will appear from the description, accompanying drawings and appended claims.

ICC

In accordance with one embodiment of this invention a molded carton is provided which includes an open top tray having a plurality of article-accommodating pockets formed therein, and a cover hingedly connected to a first side of the -tray whereby the cover may assume a closed, overlying, superimposed position with respect to the tray open top. To a second side of the tray, opposite the first side, is hingedly connected `a latching flap which is adapted to assume a position behind a depending wall of the cover, when the latter is in a closed position. The depending cover wall is provided with an aperture having a portion of the periphery thereof offset inwardly toward the flap disposed therebehind. The portion of the flap in registered relation with the cover aperture offset peripheral portion is provided with means for effecting interlocking abutting relation therewith. The flap has no portion thereof projecting outwardly from the exposed side of the cover apert-ured wall, when in interlocking engagement therewith.

For a more complete understanding of this invention reference should -be made to the drawings wherein:

FIGURE l is a top plan View of one form of an improved self-locking carton shown in a fully open position;

FIG. 2 is a front elevational view of the carton of FIG. l shown in a fully closed position;

FIG. 3 is a sectional view taken along line 3--3 of FIG. 2;

FIG. 4 is a sectional view taken along line 4-4 of FIG. l;

FIG. 5 is a fragmentary top plan view of a cover of a modified carton, shown in la fully open position;

FIG. 6 is a fragmentary ton plan view of the flap of the modied carton shown in FIG. 5;

FIG. 7 is a front elevational view of the modified carton of FIGS. 5 and 6 and shown in a fully closed position; f

FIG. 8 is a fragmentary sectional view taken along line 8-8 of FIG. 5;

FIG. 9 is a sectional view taken along line 9-9 of FIG. 7;

FIG. l0 is a fragmentary top plan view of a cover of a second modified carton, shown in a fully open position;

FIG. ll is a fragmentary top plan View of the flap of the second modified carton shown in FIG. l0;

FIG. 12 is similar to FIGS. 2 and 7 but showing the second modified carton of FIGS. l0 and 11;

FIG. 13 is similar to FIG. 1 but showing a third modied form of improved self-locking carton;

FIG. 14 is similar to FIG. 2 but showing the third modified form or carton shown in FIG. 13;

FIG. 15 is a `sectional view taken along line 15-15 of FIG. 13; and

FIG. 16 is a sectional view taken along line 16-16 of FIG. 14.

Referring now to the drawings and more particularly to FIGS. 1-4, one form 20 of an improved self-locking 3 X 4 carton is shown. Carton 20 in the illustrated embodiment is formed of molded paper-pulp and is adapted to accommodate a dozen eggs. It is to be understood, of course, that any of the illustrated cartons may be formed of thermo formed or molded plastic, press formed paperboard or any other suitable material, without departing from the scope of this invention. In a like manner the number, arrangement, and/or size of the eggaccommodating pockets :may be varied from that shown. To facilitate understanding of the instant invention, the illustrated embodiments thereof willbe directed to molded paper-pulp 3 x 4 egg cartons.

Carton 20, as shown in FIG. l, comprises an open top tray 21 having a cellular bottom 22 delimited by upwardly and outwardly extending sides 23, 24, 25, and 26. The tray sides and bottom cooperate with one another to form a plurality of egg-accommodating pockets 27 which are arranged in three parallel rows A, B, and C with each row consisting of four pockets. The upper edges of sides 23-26 form an outwardly extending flange 28 which delimits the tray open top.

Hingedly connected to the portion of flange 28 formed by side 25, which in this instance is the back side of the tray, is a cover 30. Cover 30 includes a top surface 31 and walls 32, 33, 34 and 35 delimiting and outwardly depending from surface 31. The lower edge of the walls may terminate in a continuous outwardly extending flange 36, which is similar in configuration to tray flange 28. It is the back wall 34 of the cover 30 which is made integral with a portion of tray ange 28 by the hinge connection 37. The open side of the cover 30, delimited by flange 36, is of substantially the same configuration as the open top of the tray delimited by flange 28, so that cover 30 may be folded about hinge connection 37 into a closed, overlying superimposed position, see FIG. 2, with respect to the tray 21. When the cover 30` is in its closed position, the flange 36 thereof may engage tray ange 28 and thus provide peripheral support for the cover, when a plurality of loaded cartons are arranged in stacked relation.

To provide added stiffness to the cover top surface 31, so as to resist warping or deforming of the cover when subject to a bearing load, an elongated rectilinear reinforcing rib 38 is formed therein which rigidly interconnects the back wall 34 and front'wall 32. The rib is centrally disposed between cover end walls 33 and 35 and depends from top surface 31 an amount less than the extent to which the walls depend therefrom. Other ways of providing added stiffness for the cover may be utilized, if desired, or in some instances the rib or other stiffening means may be eliminated completely. The rib or stiffening means per se forms no part of the instant invention.

Front wall 32 of cover 30 in this instance is provided with a pair of laterally spaced apertures 40 and 41 which are of like configuration. Each aperture in this instance is shown as extending up to and including a part of top surface 31. If desired, however, the upper perimetric portion of the aperture may terminate below top surface 31. In FIG. 4, it will be noted that the perimetric portion 40a or 41a which is disposed closest to ange 36 is offset inwardly, or away from the exposed surface of front wall 32, so that an abrupt or raw edge 40h or 41h of portion 40a or 41a will be disposed the greatest amount inwardly. The function of offset portions 40a and 41a will be described more fully hereinafter.

Hingedly connected to the upper edge of the front side 23 of tray 21 is a latching ap 42, see FIGS. 1 and 4. The hinge connection 43 for the ap 42 is disposed in substantially parallel relation with respect to cover hinge connection 37. As seen in FIG. 3, flap 42 is adapted to assume an upright, rearwardly extending operative position D wherein it is disposed behind the front wall 32 of the cover 30 when it is in its closed position. Because of the inherent fightback or resistance to bend of the carton material, the fiap 42, when in position D, will normally exert a positive force against the concealed surface of the cover wall 32.

Flap 42, as seen in F'IG. 1, is provided with a pair of laterally spaced openings 44 and 45. When the ap i-s in position D and cover 30 is in its closed position, see FIGS. 2 and 3, openings 44 and 45 will ibe aligned with the offset perimetric portions 40a and 41a, respectively. The configuration of each opening is such that it will readily permit the corresponding offset perimetric portion to pass therethrough. The edges 40b and 41b of offset portions 40a and 41a :are adapted to interlockingly engage the upper peripheral portions 44a and 45a, respectively, of openings 44 and 45, see FIG. 3.

In order to effect unlocking of the ap from the cover, the upper edge portion 42a, which is disposed above opening 44 or 45 and terminates in a flange providing added stiffness thereto, is pushed inwardly until the offset portions 40a and 41a of the cover front wall 32 are clear of the peripheral edge 44a and 45a, respectively, of the flap openings whereupon the cover is free to be moved to an open position.

The apertures 40 yand 41 formed in cover 30y extend upward-ly to the top surface 31 of the cover and thus, facilitate the ap portions 42a to be readily pushed inwardly, .as aforedescrifbed. It i-s important to note in FIG. 3 that there is no portion of latching flap 42 which projects outwardly beyond the exposed surface olf cover front wall 32. Thus, .b-y reason of this fact, carton 20 is not susceptible to being accidentally opened when subjected to normal handling Iby the packer, merchandiser, and customer.

Flap 42 is provided in its upper edge with a centrally disposed V-shaped slot 42h which is adapted to provide clearance -between the flap and cover stiffening rib 318, when the cover is locked in its closed position. Where no rib is provided in the cover, it is not necessary that the flap be provided with slot 42b.

FIGS. 5-9 show a modified self-locking carton 43 which is provided with a cellular tray 44 similar to tray 21, and a non-cellular cover 45 which is hingedly connected at 46 to the upper edge of the rear side 47 of tray 44. Cover 45 is provided with an outwardly depending front wall 48 having `a pair of laterally spaced apertures 50 and 51 formed therein. As noted in FIG. 7, each aperture 50 or 51 has a substantially trapezoidal configuration. The lower perimetric segment 50a and 51a of the apertures are inclined to the top surface 52 of the cover. In addition to being inclined, the perimetric segments 50a and 51a are offset inwardly, as seen in FIG. 9. The offset segments 56a and 51a: `are adapted to effect plana-r engagement with undersides of laterally extending shoulders 53 :and 54 which are formed at the opposite ends of la latching flap which is hingedly connected to the yupper edge of tray front side 56. The shoulders 53 and 54 of fiap 55 are sized so as to cover the cover apertures 50 and 51 internally when the carton is closed and thus prevent dust and/or dirt from passing through the apertures. Flap 55 -functions in the same manner as ap 42, iaforedescribed. The underside of each flap shoulder 53 or 54 is inclined in the same direction .as the cover aperture offset portion 50m or 51a and thus, a positive fairly extensive interlocking engagement is effected between the cover and flap. By reason of the inclination of the underside orf shoulders 53 and 54, the ap, when it interlocks with the cover, tends to effect self-alignment of the cover with respect to the open upper side of the tray. As in the case of carton 20, there is no portion of flap 55 which protrudes outwardly beyond the exposed surface of the front wall 48 of cover 45, when the cover is locked closed with respect to tray 44 of carton 43.

While the top surface 52 of cover 45 is illustrated as being planar, it may, if desired, have a stiffening rib fo-rmed therein in the same manner as shown in cover 30 of carton 20.

In order to release the flap shoulders 53 and 54 from locking engagement with respect to offset segments 50a and 51er, respectively, it is necessary only for the shoulders to be pushed in away from cover front wall 48. Each cover aperture 50 or 51 is of sufficient size so as to cause a substantial portion Iof each shoulder to 'be exposed therein.

A second modified lcarton 59 is shown in FIGS. l0-l2. Carton 59 is substantially the same as carton 43, except that the cover apertures 56 and 57 each have a substantially square peripheral configuration, see FIG. l2. The lower perimetric segments 56a and 57a of apertures 56 and 57 are offset inwardly away from the exposed surface of the front wall 58 of cover 60 in substantially the same way as in the case of ap 55 of carton 43, see FIG. 9.

Carton 59 is provided with a flap 61 which is hingedly -connected to the upper edge of the front side 62 of the cellular tray 631. Flap 61 is provided with laterally extending shoulders 64 and 65. The underside 64a or 65a of each shoulder 64 or 65, which is adapted to be interlockingly engaged by aperture `offset segments 56a or 57a, is disposed in substantially parallel relation with respect to the hinge connection 66 between the flap and the tray, see FIG. 11. As in the case of iiap 55, the laterally extending shoulders 64 an-d 65 of flap 61 are sized so as to close off the cover apertures 56 and 57 when the carton is closed.

The manner `of disengaging the ap 61 from cover aperture offset segments 56a and 57a is the same as that described with respect to carton 43.

FIGS. 13-16 disclose another modified carton 67. The tray 68 and cover 70 thereof are substantially the same in construction as the tray 63 and cover 60 of carton 59. The front Wall 71 of cover 70, which depends outwardly from the cover top 72, is provided with a pair of laterally spaced apertures 73. The lower peripheral segment 73a of each aperture is offset inwardly a slight amount from the exposed .surface of wall 71, see FIG. 16.

A latching ap 74, which is hingedly connected at 75 to the upper edge of the front wall 76 of the tray 68, is provided with a pair of laterally spaced apertures 77, see FIG. 13. Each aperture 77 has the upper peripheral segment 77a thereof offset outwardly a slight amount, see FIG. 16, so that, when flap 74 is in its upright operative position and cover 70 is in its fully closed position, offset segment 73a of the cover will subtend and abut the flap offset portion 77a and thus, effect interlocking of the cover and ap. It is important to note in FIG. 16 that peripheral segment 77a of the iiap 74 does not project beyond the exposed surface of cover front wall 71, when it is in interlocking engagement with the cover. In the illustrated embodiment, FIGS. 13-16, it will be noted that cover apertures 73 and Hap apertures 77 are -disposed in partial alignment with the tray pockets disposed adjacent the front side of the tray. By reason of the arrangement, the articles (eggs) disposed in these particular pockets will assist in retaining the flap and cover in locking engagement. To effect unlocking requires only a slight pushing in of the flap and a simultaneous outward exure of the cover front wall.

In all forms of the invention herein illustrated and described the offsetting of the peripheral or perimetric segment of either the aperture in the carton cover or in the ap is accomplished simultaneously with the molding of the carton and therefore does not delay or complicate the fabrication of the carton. Furthermore, the number of apertures formed in the cover front flange and the shoulders or apertures formed in the flap may be varied from that illustrated.

Thus, it will be seen that an improved molded selflocking carton has been provided which is of simple, yet sturdy construction, is inexpensive to produce, and is possessed of an effective lock in which no part thereof projects beyond the exposed surface of the cover front wall. The lock will automatically interlock with the cover of the carton and may be readily unlocked by the user of the carton when desired. The carton cover is not susceptible to being accidentally unlocked from the latching flap, when the loaded carton is subjected to normal handling by the packer, retailer, or retail customer.

While several embodiments have heretofore been disclosed and claimed, the invention is not intended to be limited thereto as further modications are contemplated, and the submitted claims are deemed to be of sufficient scope to cover such further modifications.

We claim:

1. A molded carton for use in accommodating a plurality of fragile articles, comprising an open top tray having a bottom and sides delimiting and extending upwardly from said bottom, said bottom and sides cooperating to form a plurality of article-accommodating pockets; a cover having a top and walls delimiting and depending from said top, one wall being hingedly connected to a side of said tray whereby said cover may assume a closed, overlying, superimposed position with respect to said tray open top, a second wall opposite said one wall being provided with a pair of laterally spaced apertures, each aperture having `a perimetric portion thereof offset inwardly from the exposed surface of said second wall when said cover is in said closed position; and a latching ap hingedly connected to the tray side opposite the tray side connected to said cover, said flap having a pair of exible laterally extending shoulders disposed in substantial alignment with the spacing between adjacent pockets of said tray, said ap, when in one position of hinged adjustment, being disposed behind the concealed surface of said cover second wall when said cover is in said closed position and the aperture offset perimetric portions of said cover interlockingly engaging the undersides of said flap shoulders.

2. The carton recited in claim 1 wherein the underside of each flap shoulder is angularly disposed with respect to the hinge axis of said flap.

3. The carton recited in claim 1 wherein the flap is shorter in length than the tray side to which it is hingedly connected, and said shoulders are formed in the end limits of said flap.

References Cited bythe Examiner UNITED STATES PATENTS 2,517,465 8/1950 COX 229-2.5 2,655,303 10/1953 Cox 229-25 2,843,304 7/1958 Reifers 229-45 X 2,990,094 6/ 1961 Reifers 229-25 3,215,326 1l/1965 Despres 229-25 3,223,306 12/1965 Alsman 229-25 JOSEPH R. LECLAIR, Primary Examiner.

DAVIS T. MOORHEAD, Examiner.

UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent No. 3,289,911 December 6, 196

James William Boyd et al.

It is hereby certified that error appears in the above numbered pat ent requiring correction and that the said Letters Patent should read a corrected below.

Column l, lines 25 and 33, for "aperture", each oocurre read apertured line 33, before "is" insert when the cover line 42, for "accidential" read accidental line 44, for "substantial" read a substant Signed and sealed this 19th day of September 1967.

(SEAL) Attest:

ERNEST W. SWIDER EDWARD J. BRENN Attesting Officer Commissioner of Pater 

1. A MOLDED CARTON FOR USE IN ACCOMMODATING A PLURALITY OF FRAGILE ARTICLES, COMPRISING AN OPEN TOP TRAY HAVING A BOTTOM AND SIDES DELIMITING AND EXTENDING UPWARDLY FROM SAID BOTTOM, SAID BOTTOM AND SIDES COOPERATING TO FORM A PLURALITY OF ARTICLE-ACCOMMODATING POCKETS; A COVER HAVING A TOP AND WALLS DELIMITING AND DEPENDING FROM SAID TOP, ONE WALL BEING HINGEDLY CON NECTED TO A SIDE OF SAID TRAY WHEREBY SAID COVER MAY ASSUME A CLOSED, OVERLYING, SUPERIMPOSED POSITION WITH RESPECT TO SAID TRAY OPEN TOP, A SECOND WALL OPPOSITE SAID ONE WALL BEING PROVIDED WITH A PAIR OF LATERALLY SPACED APERTURES, EACH APERTURE HAVING A PERIMETRIC PORTION THEREOF OFFSET INWARDLY FROM THE EXPOSED SURFACE OF SAID SECOND WALL WHEN SAID COVER IS IN SAID COLSED POSITION; AND A LATCHING FLAP HINGEDLY CONNECTED TO THE TRAY SIDE OPPOSITE THE TRAY SIDE CONNECTED TO SAID COVER, SAID FLAP HAVING A PAIR OF FLEXIBLE LATERALLY EXTENDING SHOULDERS DISPOSED IN SUBSTANTIAL ALIGNMENT WITH THE SPACING BETWEEN ADJACENT POCKETS OF SAID TRAY, SAID FLAP, WHEN IN ONE POSITION OF HINGED ADJUSTMENT, BEING DISPOSED BEHIND THE CONCEALED SURFACE OF SAID COVER SECOND WALL WHEN SAID COVER IS IN SAID CLOSED POSITION AND THE APERTURE OFFSET PERIMETRIC PORTIONS OF SAID COVER INTERLOCKINGLY ENGAGING THE UNDERSIDES OF SAID FLAP SHOULDERS. 